Short answer

Focus material selection and manufacturing process design on reducing the energy demands and carbon intensity of carbon fiber production and composite part fabrication.

Field: Resource Management
Source: Research Portal (Queen's University Belfast) (2015)
Method: Life Cycle Assessment (LCA)
Evidence: Strong effect

The production of carbon fiber and the manufacturing of composite parts are the most significant contributors to the carbon emissions of aerospace components. This resource management research insight is drawn from a 2015 study published in Research Portal (Queen's University Belfast). Using Life cycle assessment (lca), researchers explored how this design variable affects real-world outcomes. The key design takeaway: Focus material selection and manufacturing process design on reducing the energy demands and carbon intensity of carbon fiber production and composite part fabrication.

Study

Resource ManagementHigh ImpactStrong effect

Aerospace Composite Production: Carbon Fiber and Part Manufacturing Dominate Emissions

The production of carbon fiber and the manufacturing of composite parts are the most significant contributors to the carbon emissions of aerospace components.

Research Portal (Queen's University Belfast) · 2015

Key Findings

01Carbon fibre manufacture is a dominant source of production carbon emissions.
02Composite part manufacture is another significant contributor to production carbon emissions.
03Elevated temperature processes and associated electricity usage heavily influence the overall emissions footprint.
04The geographic location and energy sources of the supply chain have a notable impact on emissions.

Application

Design takeaway

Focus material selection and manufacturing process design on reducing the energy demands and carbon intensity of carbon fiber production and composite part fabrication.

How to apply

When designing new composite components, conduct an early-stage LCA to identify emission hotspots in the proposed supply chain and manufacturing route. Explore alternative materials or processes that offer lower carbon footprints for these identified hotspots.

Project actions

01When researching materials, look for data on their life cycle carbon footprint.
02Consider the energy sources used in manufacturing processes as a key factor in your design choices.

Method & Evidence

AimTo quantify the distribution of carbon emissions within the supply chain of a representative aerospace composite component and identify the dominant emission-producing processes.

MethodLife Cycle Assessment (LCA)

ProcedureA Life Cycle Assessment was conducted on a large structural aerospace component made from carbon fibre epoxy resin prepreg, manufactured using hand layup and autoclave cure. The study analyzed the carbon emissions associated with each stage of the supply chain, from raw material production to final part manufacturing.

ContextAerospace manufacturing, specifically civil transport aircraft components.

Variables

IV["Material production processes (e.g., carbon fiber manufacturing)","Composite part manufacturing processes (e.g., layup, curing)","Energy sources used in manufacturing","Geographic location of supply chain"]

DV["Carbon emissions (kg CO2e)"]

CV["Component type (large structural aerospace component)","Material type (carbon fibre epoxy resin prepreg)","Manufacturing methods (hand layup, autoclave cure)"]

Strengths & Limitations

Strengths

+Provides a quantitative breakdown of emissions across the supply chain.
+Identifies specific processes as key emission drivers.
+Demonstrates the sensitivity of emissions to geographic location and energy sources.

Limitations

It can be difficult to get precise carbon emission data for every step of a complex global supply chain.

Reliability & validity

The validity of the LCA depends on the accuracy and completeness of the underlying emission factor data for each supply chain stage. Reliability is enhanced by using standardized LCA methodologies.

Think critically

How might advancements in renewable energy sources and manufacturing technologies alter the dominant emission sources identified in this study?

Design Principles

"Minimize embodied energy and carbon emissions in material production and manufacturing processes."

Understanding the primary sources of carbon emissions within the supply chain allows designers and engineers to focus their efforts on the most impactful areas for reduction. This knowledge is crucial for developing more sustainable aerospace designs and manufacturing processes.

What This Means for Your Design

Making the carbon fiber and the actual composite part creates the most pollution (carbon emissions) for airplane parts.

How to use in your project

1.Use this research to justify focusing your design project's environmental impact analysis on material sourcing and manufacturing processes.

Add to My Project

Quick Cite

Paragraph starter

Research indicates that the production of carbon fiber and the subsequent manufacturing of composite parts are the most significant contributors to the carbon footprint of aerospace components, primarily due to energy-intensive, high-temperature processes. This highlights the importance of considering material sourcing and manufacturing methods when aiming to reduce environmental impact in design projects.

Source

Research Portal (Queen's University Belfast)

Understanding aerospace composite components' supply chain carbon emissions

journal · 2015

View source

Questions About This Research

What does the research say about aerospace composite production: carbon fiber and part manufacturing dominate emissions?: Focus material selection and manufacturing process design on reducing the energy demands and carbon intensity of carbon fiber production and composite part fabrication. Evidence: Research Portal (Queen's University Belfast) (2015).
Why does "Aerospace Composite Production: Carbon Fiber and Part Manufacturing Dominate Emissions" matter for design?: Understanding the primary sources of carbon emissions within the supply chain allows designers and engineers to focus their efforts on the most impactful areas for reduction. This knowledge is crucial for developing more sustainable aerospace designs and manufacturing processes.
How can designers apply this research?: Focus material selection and manufacturing process design on reducing the energy demands and carbon intensity of carbon fiber production and composite part fabrication.
What were the main findings?: Carbon fibre manufacture is a dominant source of production carbon emissions.. Composite part manufacture is another significant contributor to production carbon emissions.. Elevated temperature processes and associated electricity usage heavily influence the overall emissions footprint.. The geographic location and energy sources of the supply chain have a notable impact on emissions.
What research method was used?: Life Cycle Assessment (LCA).
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2015 journal from Research Portal (Queen's University Belfast).
What should I do differently in my next project?: When designing new composite components, conduct an early-stage LCA to identify emission hotspots in the proposed supply chain and manufacturing route. Explore alternative materials or processes that offer lower carbon footprints for these identified hotspots.
What are the limitations?: The study focused on a specific type of composite component and manufacturing method; findings may vary for different materials or processes. The LCA is predictive and relies on available data for supply chain emissions.